US7141949B2 - Low noise back EMF sensing brushless DC motor - Google Patents

Low noise back EMF sensing brushless DC motor Download PDF

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US7141949B2
US7141949B2 US11/361,214 US36121406A US7141949B2 US 7141949 B2 US7141949 B2 US 7141949B2 US 36121406 A US36121406 A US 36121406A US 7141949 B2 US7141949 B2 US 7141949B2
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windings
motor
commutation
back emf
phase
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US20060197482A1 (en
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Jonathan David Harwood
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Fisher and Paykel Appliances Ltd
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Fisher and Paykel Appliances Ltd
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P7/00—Arrangements for regulating or controlling the speed or torque of electric DC motors
    • H02P7/06—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual DC dynamo-electric motor by varying field or armature current
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/14—Electronic commutators
    • H02P6/16—Circuit arrangements for detecting position
    • H02P6/18—Circuit arrangements for detecting position without separate position detecting elements
    • H02P6/182—Circuit arrangements for detecting position without separate position detecting elements using back-emf in windings

Definitions

  • This invention relates to electronically controlled brushless DC (BLDC) motors (having permanent magnet rotors) and in particular, but not solely, to three winding motors for fractional horsepower applications such as in home appliances and healthcare equipment.
  • BLDC brushless DC
  • In a laundry machine such electronically controlled motors may be used to power the wash and spin motion of an agitator or drum and/or the wash bowl drain and recirculating pumps.
  • FIG. 1 A three phase (three stator windings) DC motor and three phase bridge commutator or inverter is shown schematically in FIG. 1 with bridge commutation switches, which could be IGBT power FETs, being connected across of DC supply having a voltage +V.
  • bridge commutation switches which could be IGBT power FETs, being connected across of DC supply having a voltage +V.
  • FIG. 2 A full pattern of the six switch states for two phase firing clockwise rotation is shown in FIG. 2 .
  • This can be interpreted as follows. To obtain maximum torque in the motor the connections would be A+ and C ⁇ to the 60 degree angle, then B+ and C ⁇ to the 120 degree angle, then B+ and A ⁇ to 180 degree angle, then C+ and A ⁇ to the 240 degree angle, then C+, B ⁇ to the 300 degree angle, and then A+ and B ⁇ to the 360 degree angle, the sequence commencing at A+ and C ⁇ again.
  • Counter-clockwise rotation of the motor is achieved by reversing the switching pattern sequence of the commutation switches.
  • the sensed BEMF waveform is cyclical and varies between trapezoidal and a near sinusoid.
  • the “zero crossings” of this waveform are due to the edge of the permanent magnet poles and provide a consistent point on the rotor to track its rotational position.
  • each winding commutation needs to be synchronous with the position of the rotor.
  • a decision is made to commutate to the next switching pattern to ensure continued rotation is accomplished. Switching must only occur when the rotor is in an appropriate angular position. This results in a closed loop feedback system for controlling speed.
  • the commutation frequency will keep pace with the rotor due to the closed loop feedback from the BEMF sensor.
  • Acceleration or de-acceleration of the rotor is accomplished by either increasing or decreasing the strength of the rotating magnetic field in the stator (by pulse width modulation (PWM) of the stator current) since the force on the rotor is proportional to the strength of the magnetic field.
  • PWM pulse width modulation
  • Maintaining a pre-determined speed under constant load involves controlling the strength of the magnetic field in the stator to ensure that the desired commutation rate is maintained.
  • To maintain a pre-determined speed of rotation under varying loads requires corresponding alteration of the strength of the magnetic field in the stator (by altering the PWM duty cycle) to compensate for changes in the load on the rotor.
  • BEMF sensing to determine rotor position has many advantages, of which one is obviating the need for external sensors, such as Hall effect sensors.
  • prior art ECMs using BEMF sensing have the problem in that the BEMF digitisers use a relatively high number of components, particularly high voltage resistors, which require excessive space on the associated printed circuit boards and increase cost.
  • WO 2005/062460 a method of sensing the BEMF in only one of the three stator windings is disclosed to address this problem.
  • the invention consists in a method of electronically commutating current to a permanent magnet rotor brushless dc motor having three phase stator windings for producing rotating magnetic flux, a three phase bridge inverter including a pair of series connected switching devices per phase and wherein motor torque is controlled by pulse width modulation of said motor current comprising the steps of:
  • each said commutation to occur at times which are substantially defined by or derived from each logic transition in said digitised signal due to zero crossings.
  • the invention consists in an electronically commutated brushless dc motor comprising:
  • stator having three phase windings adapted to be selectively commutated to produce a rotating magnetic flux
  • a three phase bridge inverter including a pair of series connected switching devices per phase with the junctions of said switching devices connected to respective stator windings;
  • digitising means coupled to one or more of said windings for digitising the back EMF induced in said one or more windings by detecting the zero crossings of said back EMF signal;
  • microcomputer operating under stored program control, said microcomputer receiving said digitized back EMF signal and outputting switching signals for said switching devices, said microcomputer storing sequences of switching device state patterns for execution to produce switching signals to cause current to be commutated through successive combinations of all three of said windings such that magnetic flux produced by said stator windings rotates in a desired direction by 60° per commutation at a speed inversely proportional to the period between commutations;
  • said stored program including routines for:
  • each said commutation to occur at times which are substantially defined by or derived from each logic transition in said digitised signal due to zero crossings.
  • a washing appliance pump including:
  • a housing having a liquid inlet and a liquid outlet
  • an electronically commutated motor which rotates said impeller, said electronically commutated motor comprising:
  • stator having three phase windings adapted to be selectively commutated to produce a rotating magnetic flux
  • a three phase bridge inverter including a pair of series connected switching devices per phase with the junctions of said switching devices connected to respective stator windings;
  • digitising means coupled to one or more of said windings for digitising the back EMF induced in said one or more windings by detecting the zero crossings of said back EMF signal;
  • microcomputer operating under stored program control, said microcomputer receiving said digitized back EMF signal and outputting switching signals for said switching devices, said microcomputer storing sequences of switching device state patterns for execution to produce switching signals to cause current to be commutated through successive combinations of all three of said windings such that magnetic flux produced by said stator windings rotates in a desired direction by 60° per commutation at a speed inversely proportional to the period between commutations;
  • said stored program including routines for:
  • the invention consists in a three winding brushless dc motor drive comprising:
  • a three phase bridge inverter including a pair of series connected switching devices per phase with the junctions of said switching devices adapted to be connected to respective stator windings of said motor;
  • digitising means adapted to be coupled to one or more of said windings for digitising the back EMF induced in said one or more windings by detecting the zero crossings of said back EMF signal;
  • microcomputer operating under stored program control, said microcomputer receiving said digitized back EMF signal and outputting switching signals for said switching devices, said microcomputer storing sequences of switching device state patterns for execution to produce switching signals to cause current to be commutated through successive combinations of all three of said windings such that magnetic flux produced by said stator windings rotates in a desired direction by 60° per commutation at a speed inversely proportional to the period between commutations;
  • said stored program including routines for:
  • FIG. 1 is a simplified circuit diagram of an electronically commutated three winding brushless DC motor
  • FIG. 2 shows the sequence of commutation switch states for two phase firing to cause clockwise rotation of the motor of FIG. 1 ,
  • FIG. 3 is a block circuit diagram of an electronically commutated brushless DC motor according to the present invention.
  • FIG. 4( a ) is a waveform diagram showing the idealised drive currents flowing through the three windings of the motor
  • FIG. 4( b ) is a corresponding waveform diagram showing the voltage across the single sensed winding of the motor of FIG. 3 ,
  • FIG. 4( c ) is a corresponding waveform diagram showing the digitised form of the voltage waveform shown in FIG. 4( b ),
  • FIG. 5 is a circuit diagram for the back EMF digitiser shown in FIG. 3 .
  • FIG. 6 shows diagrammatically an application of the present motor driving a drain and/or recirculation pump in a clothes washing machine
  • FIG. 7 is a waveform diagram showing winding current in a two phase activated motor with pulse width modulation of only the lower switching devices in the motor drive and corresponding drive voltage for the lower switching device connected to that winding,
  • FIG. 8 is a table of switching patterns for a two phase activated pulse width modulated motor drive
  • FIG. 9 is a waveform diagram showing winding current in a two phase activated motor with pulse width modulation being rotated between the upper and lower switching devices in the motor drive and corresponding drive voltage for the lower switching device connected to that winding,
  • FIG. 10 is a waveform diagram showing winding current in a pseudo three phase activated motor with pulse width modulation being rotated between the upper and lower switching devices in the motor drive and corresponding drive voltage for the lower switching device connected to that winding,
  • FIG. 11 is a table of switching patterns for a pseudo three phase activated pulse width modulated motor drive with square brackets indicating switching devices which are on for less than the commutation period in accordance with the present invention.
  • FIG. 12 is a waveform diagram showing drive voltage for upper and lower switching devices for all three phases during a full cycle for a pseudo three phase activated motor according to the present invention.
  • FIG. 3 shows one preferred form of the electronically commutated motor of the present invention in block diagram form.
  • the main hardware blocks are a permanent magnet three winding motor 21 , motor winding commutation circuit 22 , DC power supply 23 , back EMF digitiser 24 and a programmed microcomputer 25 .
  • the microcomputer 25 will usually be the appliance microprocessor which will be responsible for all other appliance control functions; including control of a main motor for spin and wash actions in the case of a clothes washing machine.
  • the present electronically commutated motor (ECM) system is described in relation to a preferred form of motor having a stator with three windings (or phases) A, B and C and six salient poles. Other stator configurations could be used.
  • the motor has a four pole permanent magnet rotor, although a different number of poles could be adopted.
  • the windings A, B and C are connected together in star configuration in this embodiment as indicated in FIG. 3 .
  • the motor drive (inverter or commutation circuit) 22 includes pairs of switching devices in the form of IGBTs or power field effect transistors (FETs) which are connected across the direct current power supply 23 in a bridge configuration to commutate each of windings A, B and C in the manner already described with reference to FIGS. 1 and 2 where they are designed A+/A ⁇ , B+/B ⁇ and C+/C ⁇ .
  • the winding inductances ensure the winding current that results is more sinusoidal than the rectangular voltage waveforms.
  • Each of the six switching devices making up the upper and lower switches for each motor phase is switched by gate signals a+, a ⁇ , b+, b ⁇ , c+, c ⁇ produced by microcomputer 25 .
  • DC power supply 23 supplies the DC voltage which is applied across each switching device pair.
  • BEMF digitiser 24 receives an input signal from the switched end of motor phase A for the purposes of monitoring the back EMF induced by rotation of the rotor which provides rotor position information. In the preferred embodiment only the output from a single motor winding (in this example winding A) is used for this purpose as disclosed in WO 2005/062460.
  • BEMF digitiser 24 supplies at its output a digital signal (see FIG. 4( c )) representative of the analogue signal at its input (see FIG. 4( b )) and derives the logic levels by comparator techniques as will be described.
  • the digital output signal will include periodic logic transitions A 1 and A 2 which correspond to the “zero crossings” Z 1 and Z 2 of the analogue BEMF voltage induced in phase winding A as a rotor pole passes a winding pole associated with that phase.
  • the BEMF digitiser 24 may be implemented in hardware as shown in FIG. 5 and disclosed in WO 2005/062460 (incorporated herein by reference) or may be implemented in software in microprocessor 25 .
  • a start routine 30 causes the commutation control pulse generator 29 to produce pulses on output ports a+ to c ⁇ reflecting the switch patterns shown in FIG. 2 .
  • Each of the six switch patterns is successively retrieved in turn from memory 28 .
  • Control pulses for the commutation switches are synthesised by the commutation control pulse generator routine 29 which includes a pointer value which points to the location of the switching state pattern in table 28 which is required to produce the next commutation for the particular direction of rotation required of motor 21 .
  • Six commutation drive signals are required to be synthesised although only two of these change state on each commutation.
  • the switch patterns are cycled continuously at a low speed to produce a stator flux which rotates at the same speed to induce the rotor to rotate and synchronise with that speed.
  • commutation control is triggered by the logic transitions in the back EMF signal at input port 27 in a closed loop mode and the start routine exited.
  • Commutations may be triggered by actual detected zero-crossings in the BEMF signal in the currently unused winding or, where only one winding is monitored as in the preferred embodiment (eg winding A), the logic transitions A 1 and A 2 in signal 45 are directly used while triggers for the commutation control pulse generator 29 for phases B and C must be derived by extrapolation as disclosed in WO 2005/062460.
  • the synthesised commutation control pulses are pulse width modulated when being supplied to the commutation circuit 22 .
  • a routine 32 imposes a duty cycle on the pulses which are synthesised by routine 29 appropriate to the commutation devices through which motor current is to flow in accordance with the present value of duty cycle held in location 33 .
  • the duty cycle is varied to vary the applied voltage across the stator windings to accelerate and decelerate motor 21 and to accommodate varying loads on the rotor since rotor torque is proportional to motor current and this is determined by the duty cycle of the pulse width modulation (PWM). In some applications it may be sufficient to only pulse width modulate the lower bridge devices in the commutation circuit 22 .
  • PWM pulse width modulation
  • phase A of a two phase activated back EMF sensing motor with pulse width modulation of the lower switching devices only is shown in FIG. 7 along with the switching input signal for the lower switching device in the bridge for that phase (A ⁇ ). It will be noted that the current waveform I A is far from sinusoidal and this results in perturbations in the motor torque and hence vibrations which may produce an unacceptable level and quality of motor noise.
  • the present invention proposes a methodology to achieve this with modest implementation costs. Referring to FIG. 7 the main departures of waveform I A from sinusoidal can be attributed to the notch in the maximum current amplitude excursions and the steep decay of current to zero prior to polarity reversal.
  • the present invention also provides for elimination of the notch in the current waveform peak values. This is achieved by activating the third phase for a period for less than the full commutation period (that is less than 60° flux rotation angle) so as to ensure the phase is inactivated in the region of the back EMF zero crossing.
  • This pseudo three phase activation allows back EMF zero crossing detection to be used while obtaining some of the advantages of three phase activation.
  • phase A The waveforms for partial activation of the third phase (pseudo-three phase activation) when it would normally be off are shown for phase A in FIG. 10 .
  • the A ⁇ switching device is turned on (and pulse width modulated) in the 120° to 180° flux rotation sector for a short period (i.e. after the 60° to 120° sector when it is continuously ON) when it would normally have been turned off following its being switched on for the preceding two 60° sectors.
  • the notch at peak value of phase current I A has now been substantially corrected.
  • Activation of three phases also reduces peak winding currents. This reduces heat dissipated in the switching devices. This in turn allows for a higher switching frequency which also serves to reduce motor noise.
  • the waveforms for the switching device driving signals for pseudo three phase activation of the motor (and rotating PWM) are shown in FIG. 12 and the corresponding switch pattern table is shown in FIG. 11 with switch ON periods less than 60° being indicated by the use of square brackets.
  • pseudo three phase activation depending on the particular switch pattern, either two high side or two low side switching devices are ON.
  • the two switching devices on the same level are those which are pulse width modulated to avoid circulating currents which distort the current waveform and reduce efficiency when switches on opposite levels are simultaneously pulse width modulated. It is important that when the third phase is activated that its pulse width modulated ON period is terminated sufficiently in advance of the potential zero crossing time of the rotor generated back EMF.
  • the ON period is fixed—say 300 ⁇ S.
  • the third phase activation time is varied with motor speed thereby improving the current waveform smoothing.
  • the computed value of third phase activation time must be subject to modification to maintain a predetermined minimum head space between the termination of phase current decay to zero and the point of back EMF zero crossing. This is particularly significant as the current decay period is proportional to the forward current which itself is proportional to the motor load.
  • PWM duty cycles in this technique are pre-stored using values derived empirically or from a model and vary motor speed.
  • An End of Current Pulse routine 51 detects the completion of the current pulse at the selected time interval, from the filtered digitized back EMF signal from routine 48 .
  • a Phase Conduction Control routine 49 calculates the reduced conduction time for the third phase and passes it to Phase Conduction Timer routine 50 . This time is based on motor speed and routine 49 accepts speed data from routine 34 . In a simpler embodiment with a less powerful microcomputer this time may be fixed, say at 300 ⁇ S, and routine 49 is not required.
  • Commutation data from routine 29 provides the start time for the third phase conduction time and this is passed to the Phase Conduction timer routine 50 .
  • Routine 49 also measures the time between current pulse termination to zero crossing detect by signals from End of Ipulse detect routine 51 and from routine 46 . If a predetermined time margin is compromised it sends a signal to routine 33 to reduce PWM duty cycle on all phases to avoid loss of synchronism.
  • routine 49 sends a signal to routine 33 to modify PWM on each phase independently at commutation angle intervals to produce a motor current which more accurately approximates a sinusoid. To do this routine 49 requires switching device state patterns from routine 29 .
  • the Phase Conduction Timer routine 50 disables BEMF signal from being analysed while third phase conduction occurs by sending a signal to routine 48 . It also turns off PWM on the active third phase when phase conduction time has elapsed by signal to PWM duty cycle routine 33 .

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Control Of Motors That Do Not Use Commutators (AREA)
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EP (1) EP1701437A2 (de)
JP (1) JP2006254693A (de)
KR (1) KR20060096931A (de)
AU (1) AU2006200913B2 (de)
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